2009 SERVICE MANUAL YFM25RY YFM25RSEY YFM25RSE2Y LIT-11616-22-09 4D3-28197-11
EAS20040 YFM25RY/YFM25RSEY/YFM25RSE2Y SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, April 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. • Sub-section titles appear in smaller print than the section title “2”.
EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. TIP The following symbols are not relevant to every vehicle. No SYMBOL DEFINITION 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque T. R.
No SYMBOL 10 DEFINITION Gear oil G 11 Molybdenum-disulfide oil M 12 Brake fluid BF 13 B Wheel-bearing grease 14 LS Lithium-soap-based grease 15 M Molybdenum-disulfide grease 16 S Silicone grease 17 Apply locking agent (LOCTITE®) LT 18 New Replace the part
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8
GENERAL INFORMATION IDENTIFICATION ..........................................................................................1-1 VEHICLE IDENTIFICATION NUMBER...................................................1-1 MODEL LABEL.......................................................................................1-1 IMPORTANT INFORMATION .......................................................................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-2 REPLACEMENT PARTS..............
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. 1 EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
IMPORTANT INFORMATION EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” on page 1-5. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1. 2. 3. 4.
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • Lead • Coupler • Connector 2. Check: • Lead • Coupler • Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. TIP • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3).
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. TIP • For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No.
SPECIAL TOOLS Tool name/Tool No. Illustration Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Reference pages 5-19 Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066 5-19 Valve lapper 90890-04101 Valve lapping tool YM-A8998 5-20 PTT wrench 46 90890-06588 Axle nut wrench (46 mm) YM-37134 4-13, 4-14 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 7-39 Digital tachometer 90890-06760 YU-39951-B 3-5, 3-8 Yamaha bond No.
SPECIFICATIONS GENERAL SPECIFICATIONS ......................................................................2-1 ENGINE SPECIFICATIONS..........................................................................2-4 CHASSIS SPECIFICATIONS......................................................................2-10 ELECTRICAL SPECIFICATIONS...............................................................2-12 TIGHTENING TORQUES............................................................................
GENERAL SPECIFICATIONS EAS29110 GENERAL SPECIFICATIONS Model Model 4D3D/4D3H/4D3M Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 1625 mm (64.0 in) 1070 mm (42.1 in) 1040 mm (40.9 in) 730 mm (28.7 in) 1110 mm (43.7 in) 100 mm (3.9 in) 2900 mm (114 in) Weight With oil and fuel 150.
GENERAL SPECIFICATIONS Spark plug (s) Manufacturer/model Spark plug gap Clutch type NGK/DR7EA 0.6–0.7 mm (0.024–0.028 in) Wet, multiple-disc Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation 1st 2nd 3rd 4th 5th Spur gear 76/22 (3.455) Chain drive 38/14 (2.714) Constant mesh 5-speed Left foot operation 37/13 (2.846) 33/18 (1.833) 29/21 (1.381) 27/24 (1.125) 28/29 (0.
GENERAL SPECIFICATIONS Rear suspension Type Spring/shock absorber type Wheel travel Swingarm Coil spring/gas-oil damper 200 mm (7.9 in) Electrical system Ignition system Charging system Model Voltage, capacity DC. CDI AC magneto YTZ7S 12 V, 6.0 Ah Headlight Bulb type Bulb voltage, wattage × quantity Headlight Tail/brake light Krypton bulb 12 V, 30.0/30.0 W × 2 12 V, 5.0/21.0 W × 1 (4D3D) 12 V, 0.5/3.9 W × 1 (4D3H, 4D3M) 12 V, 1.
ENGINE SPECIFICATIONS EAS29120 ENGINE SPECIFICATIONS Cylinder head Volume Warpage limit 20.50–21.50 cm3 (1.25–1.31 cu.in) 0.05 mm (0.0020 in) Cylinder Bore Wear limit 74.000–74.016 mm (2.9134–2.9140 in) 74.100 mm (2.9173 in) Camshaft Drive system Camshaft lobe dimensions Intake A Limit Intake B Limit Exhaust A Limit Exhaust B Limit Chain drive (right) 36.890–36.990 mm (1.4524–1.4563 in) 36.790 mm (1.4484 in) 30.111–30.211 mm (1.1855–1.1894 in) 30.011 mm (1.1815 in) 36.891–36.991 mm (1.4524–1.
ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter A (intake) Valve head diameter A (exhaust) 0.05–0.10 mm (0.0020–0.0039 in) 0.10–0.15 mm (0.0039–0.0059 in) 33.90–34.10 mm (1.3346–1.3425 in) 28.40–28.60 mm (1.1181–1.1260 in) Valve face width B (intake) Valve face width B (exhaust) 2.26 mm (0.0890 in) 2.26 mm (0.0890 in) Valve seat width C (intake) Limit Valve seat width C (exhaust) Limit 0.90–1.10 mm (0.0354–0.0433 in) 1.
ENGINE SPECIFICATIONS Valve spring Inner spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate K1 (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Installed compression spring force (exhaust) Spring tilt (intake) Spring tilt (exhaust) Winding direction (intake) Winding direction (exhaust) Outer spring Free length (intake) Limit Free length (exhaust) Limit In
ENGINE SPECIFICATIONS Piston Piston-to-cylinder clearance Limit Diameter D Height H 0.010–0.025 mm (0.0004–0.0010 in) 0.15 mm (0.0059 in) 73.983–73.998 mm (2.9127–2.9133 in) 5.0 mm (0.20 in) Offset Offset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston-pin-to-piston-pin-bore clearance Limit 0.25 mm (0.0098 in) Intake side 17.002–17.013 mm (0.6694–0.6698 in) 17.043 mm (0.6710 in) 16.991–17.000 mm (0.6689–0.6693 in) 16.971 mm (0.6681 in) 0.002–0.022 mm (0.0001–0.
ENGINE SPECIFICATIONS Crankshaft Width A Runout limit C Big end side clearance D Limit Big end radial clearance E 69.25–69.30 mm (2.726–2.728 in) 0.03 mm (0.0012 in) 0.350–0.650 mm (0.0138–0.0256 in) 0.50 mm (0.0197 in) 0.010–0.025 mm (0.0004–0.0010 in) Balancer Balancer drive method Gear Clutch Friction plate thickness Limit Plate quantity Clutch plate thickness Plate quantity Clutch plate warpage limit Clutch spring free length Limit Spring quantity Clutch release method Push rod 2 bending limit 2.
ENGINE SPECIFICATIONS Carburetor ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilot air jet 2 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Float height 4D31 00 #133.8 #140 5DH66-1 P-0M (922) #85 #170 0.9 #25 0.8 0.8 0.8 2 #55 0.5 #100 13.0 mm (0.51 in) Idling condition Engine idling speed CO% Intake vacuum Oil temperature 1500–1600 r/min 4.0–5.0% 34.0 kPa (255 mmHg, 10.0 inHg) 55.0–65.0 °C (131.0–149.
CHASSIS SPECIFICATIONS EAS29130 CHASSIS SPECIFICATIONS Front suspension Shock absorber travel 90.7 mm (3.57 in) (4D3D) 88.4 mm (3.48 in) (4D3H, 4D3M) 248.5 mm (9.78 in) (4D3D) 224.6 mm (8.84 in) (4D3H, 4D3M) 23.00 N/mm (2.35 kgf/mm, 131.33 lbf/in) 0.0–90.7 mm (0.00–3.57 in) (4D3D) 0.0–88.4 mm (0.00–3.48 in) (4D3H, 4D3M) No Spring free length Spring rate K1 Spring stroke K1 Optional spring available Rear suspension Rear shock absorber assembly travel Spring free length Installed length 87.0 mm (3.
CHASSIS SPECIFICATIONS Front brake Type Disc outside diameter × thickness Brake disc thickness limit Brake disc deflection limit Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Recommended fluid Dual disc brake 161.0 × 3.5 mm (6.34 × 0.14 in) 3.0 mm (0.12 in) 0.15 mm (0.006 in) 4.4 mm (0.17 in) 1.5 mm (0.06 in) 4.4 mm (0.17 in) 1.5 mm (0.06 in) 12.7 mm (0.50 in) 27.00 mm (1.
ELECTRICAL SPECIFICATIONS EAS29140 ELECTRICAL SPECIFICATIONS System voltage System voltage 12 V Ignition system Ignition timing (B.T.D.C.) Advanced timing (B.T.D.C.) Advancer type 10.0 °/1550 r/min 24.4 °/5000 r/min Digital DC. CDI Pickup coil resistance CDI unit model/manufacturer 248-372 Ω (R–W) 4D3/YAMAHA Ignition coil Model/manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance 2JN/YAMAHA 6.0 mm (0.24 in) 0.18–0.28 Ω 6.32–9.
ELECTRICAL SPECIFICATIONS Headlight relay Model/manufacturer Coil resistance G8HN-1C4T-DJ-Y52/OMRON 94.5–115.5 Ω Circuit breaker Circuit breaker type Fuse Fuse Fuse Reserve 15.0 A 15.
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks See TIP Cylinder head bolt (upper) M8 4 24 Nm (2.
TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Primary drive gear nut M16 1 80 Nm (8.0 m·kg, 59 ft·lb) Clutch boss nut M16 1 75 Nm (7.5 m·kg, 55 ft·lb) Clutch spring screw Push lever adjusting screw locknut Push lever shaft bolt Chain case cover bolt M6 M6 M8 M10 5 1 1 2 8 Nm (0.8 m·kg, 5.9 ft·lb) 8 Nm (0.8 m·kg, 5.9 ft·lb) 12 Nm (1.2 m·kg, 8.9 ft·lb) 10 Nm (1.0 m·kg, 7.4 ft·lb) Drive sprocket nut M18 1 110 Nm (11.
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Q’ty Tightening torque Remarks size Engine upper stay and frame M8 2 33 Nm (3.3 m·kg, 24 ft·lb) Engine upper stay and engine M10 1 66 Nm (6.6 m·kg, 49 ft·lb) Engine lower stay and frame M8 4 33 Nm (3.3 m·kg, 24 ft·lb) Engine lower stay and engine M10 1 40 Nm (4.0 m·kg, 30 ft·lb) Engine and frame M10 2 66 Nm (6.6 m·kg, 49 ft·lb) Drive chain guide roller and frame M8 1 23 Nm (2.3 m·kg, 17 ft·lb) Engine skid plate and frame M6 4 7 Nm (0.7 m·kg, 5.
TIGHTENING TORQUES Item Front brake disc and front wheel hub Rear wheel and rear wheel hub Rear axle and rear wheel hub Rear axle ring nut Rear axle ring nut set bolt Rear brake caliper and brake caliper bracket Rear brake disc and brake disc bracket Adjusting bolt locknut (parking brake) Driven sprocket and sprocket bracket Front brake pipe flare nut Front brake master cylinder and brake hose Front brake caliper and brake hose Front brake pad retaining bolt Front brake caliper bleed screw Front brake hose
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings Cylinder head bolts (bearing surface of bolts) E E Cylinder head bolts (thread part) M Cylinder body surface Crankshaft journals Connecting rod small end and big end Piston pin Piston surface Boss periphery Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Rocker arm shafts (intake and exhaust) Camshaft lobes
LUBRICATION POINTS AND LUBRICANT TYPES 2-20
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-21
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil cooler 5. Oil filter element 6. Cylinder head 7. Camshaft 8. Pin with hole 9. Crankshaft 10.Drive axle 11.
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8.
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil hose 1 3.
CABLE ROUTING EAS20430 CABLE ROUTING 2-29
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. 8. Clutch switch lead Clutch cable Front brake hose 1 Front brake light switch lead Throttle cable Plastic band Parking brake cable Handlebar switch lead A. Route the clutch cable and parking brake cable through the guide of the handlebar protector. B. Route the clutch cable in front of the parking brake cable. C. Route the front brake hose and throttle cable through the guide of the handlebar protector. D.
CABLE ROUTING 2-31
CABLE ROUTING O. When installing the brake pipe, place the marking on top and tighten the above flare nut first. P. Route the rear brake light switch lead under the bracket. Q. Route the rear brake light switch lead, neutral switch lead, air vent hose, carburetor overflow hose and parking brake cable through the bracket. R. Route the rear brake light switch lead between the bracket and rear brake reservoir. S. Route the neutral switch lead and rear brake light switch lead as shown in the illustration. 1.
CABLE ROUTING 2-33
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. 8. Rear brake reservoir Rear brake light switch Clip Rear brake reservoir hose Rear brake master cylinder Parking brake cable Rear brake hose Rear brake caliper A. Make sure that the end of the clip is facing downward. B. Set the rear brake reservoir hose with the positioning yellow paint mark pointing down. C. Install the rear brake hose in the direction shown in the illustration. D. Insert the rear brake hose until it contacts the projection. E.
CABLE ROUTING 2-35
CABLE ROUTING 4D3D 1. Clutch switch lead 2. Handlebar switch lead 3. Bolt 4. Hexagonal head bolt 5. Main harness 6. Air vent hose 7. Clamp 8. Battery negative lead 9. AC magneto lead 10.Carburetor overflow hose 11.Neutral switch lead 12.Starter motor lead 13.Ignition coil spark plug lead 14.Ignition coil 15.Drain hose 16.Frame complete 17.Damper plate 18.Seat pad 19.Rear brake light switch lead 20.Carburetor warmer lead 21.Side cover 22.Breather hose 23.Air filter joint 24.Air filter case A.
CABLE ROUTING 2-37
CABLE ROUTING 4D3H/4D3M 1. Clutch switch lead 2. Handlebar switch lead 3. Bolt 4. Hexagonal head bolt 5. Main harness 6. Air vent hose 7. Clamp 8. Battery negative lead 9. AC magneto lead 10.Carburetor overflow hose 11.Neutral switch lead 12.Starter motor lead 13.Ignition coil spark plug lead 14.Ignition coil 15.Drain hose 16.Frame complete 17.Damper plate 18.Seat pad 19.Rear brake light switch lead 20.Carburetor warmer lead 21.Side cover 22.Breather hose 23.Air filter joint 24.Air filter case 25.
CABLE ROUTING 2-39
CABLE ROUTING 1. Indicator light 2. Coupler joint 3. Main switch lead 4. Main switch 5. Front brake light switch lead 6. Throttle cable 7. Air vent hose 8. Clutch switch lead 9. Handlebar switch lead 10.Parking brake cable 11.Clutch cable 12.Flange bolt 13.Headlight lead 14.Indicator light lead 15.Rear brake reservoir 16.Rear brake light switch lead 17.Battery negative lead 18.Carburetor warmer lead 19.Starter motor lead 20.Rectifier/regulator 21.Main harness 22.Frame complete 23.Clamp A.
CABLE ROUTING 2-41
CABLE ROUTING 1. Battery 2. CDI unit 3. Band 4. Starter relay lead 5. Starter relay 6. Taillight lead 7. Battery negative lead 8. AC magneto coupler 9. Starter motor lead 10.Headlight relay 11.Neutral relay 12.Damper 13.CDI unit lead 14.Relay lead A. Route the starter relay lead under the starter motor lead. B. After connecting the battery negative lead, push the sag in the box. C.
CABLE ROUTING 2-43
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .........................................................................3-1 INTRODUCTION ....................................................................................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM...............................................................................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART.....................3-2 ENGINE....................................................................
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for 4D3H, 4D3M)..................................................................................3-28 CHECKING THE TIRES .......................................................................3-29 CHECKING THE WHEELS ..................................................................3-31 CHECKING AND LUBRICATING THE CABLES ..................................3-31 LUBRICATING THE LEVERS...............................................................
PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE EAS4D3F012 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) 20 80 160 160 320 hours 1 Air filter element Every 20–40 hours (more often in wet or dusty areas) • Clean and replace if necessary. 2 * Clutch • Check operation and adjust if necessary. √ 3 * Front brake • Check operation and correct if necessary.
PERIODIC MAINTENANCE INITIAL NO. ITEM Lights and 25 * switches CHECK OR MAINTENANCE JOB Whichever comes first • Check operation and correct if necessary. • Adjust headlight beams. EVERY month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 √ √ √ √ √ TIP • The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
ENGINE EAS20472 ENGINE Valve clearance (cold) Intake valve 0.05–0.10 mm (0.0020–0.0039 in) Exhaust valve 0.10–0.15 mm (0.0039–0.0059 in) EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. TIP • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ENGINE e. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • All removed parts TIP For installation, reverse the removal procedure. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Adjust: • Valve clearance EAS29150 ADJUSTING THE ENGINE IDLING SPEED 1. Start the engine and let it warm up for several minutes. 2.
ENGINE 5. Detach: • Digital tachometer 6. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-6. Throttle cable free play 2.0–4.0 mm (0.08–0.16 in) EAS20660 ADJUSTING THE THROTTLE CABLE FREE PLAY TIP If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side. TIP Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1.
ENGINE EAS29170 EAS20690 ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum position. Screwing in the adjusting screw stops the engine speed from increasing. 1. Measure: • Speed limiter length “a” Out of specification → Adjust. CHECKING THE SPARK PLUG 1. Disconnect: • Spark plug cap 2.
ENGINE 7. Install: • Spark plug c. Check that the stationary pointer “a” is within the firing range “b” on the pickup coil rotor. Incorrect firing range → Check the ignition system. Spark plug 18 Nm (1.8 m·kg, 13 ft·lb) TIP Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • Spark plug cap EAS20700 CHECKING THE IGNITION TIMING TIP Prior to checking the ignition timing, check the wiring connections of the entire ignition system.
ENGINE 4. Remove: • Spark plug b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. ECA13340 EWA4D3F002 WARNING Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinder. To prevent sparking, ground spark plug lead before cranking the engine. c.
ENGINE • Do not screw the dipstick “1” in when checking the oil level. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. TIP Type YAMALUBE 4 (10W-40) or SAE 10W-40, YAMALUBE 4 (20W50) or SAE 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20800 CHANGING THE ENGINE OIL 1. Place the vehicle on a level surface. 2.
ENGINE 6. Drain: • Engine oil (completely from the crankcase) 7. If the oil filter element is also to be replaced, perform the following procedure. Engine oil quantity Without oil filter element replacement 1.25 L (1.32 US qt, 1.10 Imp.qt) With oil filter element replacement 1.35 L (1.43 US qt, 1.19 Imp.qt) Total amount 1.60 L (1.69 US qt, 1.41 Imp.qt) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter element cover “1” and oil filter element “2”. b. Install new O-ring “3”. 10.
ENGINE EAS20870 EAS20941 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • Clutch cable free play “a” Out of specification → Adjust. CLEANING THE AIR FILTER ELEMENT TIP On the bottom of the air filter case is a check hose “1”. If dust or water or both collects in this hose, clean the air filter element and air filter case. Clutch cable free play (lever end) 5.0–10.0 mm (0.20–0.39 in) 1. Remove: • Seat Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Air filter case cover “1” 2.
ENGINE 5. Check: • Air filter element Damage → Replace. 6. Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping. Air filter oil grade Foam air filter oil or equivalent oil 7. Install: • Air filter element frame 8. Apply: • Lithium-soap-based grease On the matching surface “a” on air filter element. 4.
ENGINE 2. Check: • Tightening torque • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Carburetor Refer to “CARBURETOR” on page 6-3. 2. Check: • Carburetor joint • Intake manifold Cracks/damage → Replace. Refer to “CARBURETOR” on page 6-3. 3. Install: • Carburetor Refer to “CARBURETOR” on page 6-3. • Air filter case • Rear fender • Front fender • Seat Refer to “GENERAL CHASSIS” on page 4-1. Exhaust pipe nut 18 Nm (1.8 m·kg, 13 ft·lb) Muffler joint bolt 20 Nm (2.
ENGINE d. Insert the tailpipe and gasket “3” into the muffler and align the bolt holes. e. Insert the bolts and tighten it. Spark arrester bolt 11 Nm (1.1 m·kg, 8.
CHASSIS EAS29360 CHASSIS EAS21170 ADJUSTING THE FRONT DISC BRAKE 1. Check: • Brake lever free play “a” Out of specification → Bleed the front brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. ECA13490 Brake lever free play (at the end of the brake lower) 0 mm (0 in) After adjusting the brake lever position, make sure there is no brake drag.
CHASSIS EWA14900 WARNING After this adjustment is performed, lift the front and rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Place the vehicle on a level surface. A. Front brake B.
CHASSIS EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Remove: • Front wheels Refer to “FRONT WHEEL” on page 4-4. 2. Operate the brake. 3. Check: • Front brake pad Wear indicators groove almost disappeared “a” → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-15. 3. Check: • Brake hose clamp Loose → Tighten the clamp bolt. 4. Hold the vehicle upright and apply the brake several times. 5.
CHASSIS 3. Hold the vehicle upright and apply the front brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the damaged hose. Refer to “REAR BRAKE” on page 4-27. EAS29210 ADJUSTING THE PARKING BRAKE 1. Check: • Parking brake cable end length “a” Out of specification → Adjust. Parking brake cable end length 64.0–68.0 mm (2.52–2.
CHASSIS c. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. A. Front B. Rear d.
CHASSIS k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17. EAS21390 ADJUSTING THE DRIVE CHAIN SLACK TIP • Measure the drive chain slack halfway between the drive axle and the rear axle. • When checking and adjusting the drive chain slack, there should be no weight on the vehicle and all tires must be touching the ground. EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation.
CHASSIS age these O-rings. Therefore, use only kerosene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains ECA4D3F005 EAS29280 CHECKING THE STEERING SYSTEM 1. Place the vehicle on a level surface. 2.
CHASSIS 4. Raise the front end of the vehicle so that there is no weight on the front wheels. 5. Check: • Ball joints and wheel bearings Move the wheels laterally back and forth. Excessive free play → Replace the front arms (upper and lower) and/or wheel bearings. EAS29290 ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • Toe-in Out of specification → Adjust. C. Forward ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: • Toe-in Toe-in (with tire touching the ground) 9.0–19.0 mm (0.
CHASSIS 3. Check: • Operation Pump the front shock absorber assembly up and down several times. Unsmooth operation → Replace front shock absorber assembly. Refer to “FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES” on page 4-47. EAS29310 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3D) d. Tighten the rod end locknuts of both tierods. EWA14920 WARNING Locknut (tie-rod end) 15 Nm (1.5 m·kg, 11 ft·lb) Always adjust the spring preload for both front shock absorber assemblies to the same setting.
CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS4D3F031 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3H, 4D3M) EWA14920 TIP WARNING Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjustment. Always adjust the spring preload for both front shock absorber assemblies to the same setting. Uneven adjustment can cause poor handling and loss of stability. d. Tighten the locknut. Spring preload Front shock absorber locknut 42 Nm (4.
CHASSIS Rebound damping adjusting positions Minimum 20 clicks in direction: “b”* Standard 12 clicks in direction: “b”* Maximum 3 clicks in direction: “b”* Compression damping (slow compression damping) adjusting positions Minimum 20 clicks in direction: “b”* Standard 10 clicks in direction: “b”* Maximum 1 clicks in direction: “b”* * With the adjusting screw fully turned-in direction “a” * With the adjusting screw fully turned-in direction “a” TIP Make sure that the position indicator marks “c” are alig
CHASSIS EAS29330 Compression damping (fast compression damping) adjusting positions Minimum 4 turns in direction: “b”* Standard 2 turns in direction: “b”* Maximum 0 turns in direction: “b”* ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for 4D3D) 1. Adjust: • Spring preload ECA4D3F006 Never attempt to turn the adjusting nut beyond the maximum or minimum setting. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Elevate the rear wheels by placing a suitable stand under the frame. b. Loosen the locknut “1”. c.
CHASSIS TIP Spring preload adjusting length “c” Minimum 232.0 mm (9.13 in) Standard 228.0 mm (8.98 in) Maximum 220.0 mm (8.66 in) Be sure to remove all dirt and mud from around the locknut and adjusting nut before adjustment. d. Tighten the locknut. Rear shock absorber locknut 42 Nm (4.2 m·kg, 31 ft·lb) TIP Always tighten the locknut against the adjusting nut, then torque it to specification.
CHASSIS Rebound damping adjusting positions Minimum 20 clicks in direction: “b”* Standard 12 clicks in direction: “b”* Maximum 3 clicks in direction: “b”* Compression damping adjusting positions Minimum 12 clicks in direction: “b”* Standard 7 clicks in direction: “b”* Maximum 2 clicks in direction: “b”* * With the adjuster fully turned-in direction “a” * With the adjusting screw fully turned-in direction “a” TIP Make sure that the position indicator marks “c” are aligned when the shock absorber is set t
CHASSIS • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading. Front tire Size AT20 × 7-10 Manufacturer/model DUNLOP/KT201 Rear tire Size AT19 × 10-9 Manufacturer/model DUNLOP/KT205A Tire pressure EWA14960 WARNING • Tire pressure below the minimum specification could cause the tire to dislodge from the rim under severe riding conditions. The following are minimums: • Front 24.5 kPa (0.
CHASSIS Replace damaged outer cable and inner cables as soon as possible. EWA13190 WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 1. Check: • Outer cable Damage → Replace. 2. Check: • Cable operation Rough movement → Lubricate or replace. Recommended lubricant Yamaha chain and cable lube or engine oil TIP Hold the cable end up and apply several drops of lubricant to the cable.
ELECTRICAL SYSTEM EAS21750 EWA13320 ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 7-27. 5. Install: EAS21770 • Headlight bulb New Secure the new headlight bulb with the headlight unit. CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 7-27.
ELECTRICAL SYSTEM ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or “b”. Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered.
CHASSIS GENERAL CHASSIS....................................................................................4-1 FRONT WHEEL ............................................................................................4-4 REMOVING THE FRONT WHEELS.......................................................4-5 CHECKING THE FRONT WHEELS .......................................................4-5 CHECKING THE FRONT WHEEL HUBS...............................................4-5 CHECKING THE FRONT BRAKE DISCS .............
REPLACING THE REAR BRAKE PADS ..............................................4-32 REMOVING THE REAR BRAKE CALIPER..........................................4-33 DISASSEMBLING THE REAR BRAKE CALIPER................................4-34 CHECKING THE REAR BRAKE CALIPER ..........................................4-34 ASSEMBLING THE REAR BRAKE CALIPER......................................4-34 INSTALLING THE REAR BRAKE CALIPER.........................................4-35 REMOVING THE REAR BRAKE MASTER CYLINDER ......
CHAIN DRIVE .............................................................................................4-57 REMOVING THE DRIVE CHAIN ..........................................................4-58 CHECKING THE DRIVE CHAIN ..........................................................4-58 CHECKING THE DRIVE SPROCKET ..................................................4-59 CHECKING THE REAR WHEEL SPROCKET .....................................4-59 CHECKING THE SPROCKET BRACKET ......................................
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seat, front fender and headlights Order Job/Parts to remove Q’ty Remarks TIP 1 Seat 1 Pull back the seat lock lever, than pull up on the rear of the seat. 2 3 4 5 6 7 8 9 Indicator light coupler Front panel Plate Main switch coupler Front fender Headlight coupler Left headlight Right headlight 1 1 1 1 1 2 1 1 Disconnect. Disconnect. Disconnect. For installation, reverse the removal procedure.
GENERAL CHASSIS Removing the foot protectors and engine skid plate Order 1 2 3 Job/Parts to remove Left foot protector Right foot protector Engine skid plate Q’ty 1 1 1 Remarks For installation, reverse the removal procedure.
GENERAL CHASSIS Removing the rear fender and air filter case Order 1 2 Job/Parts to remove Seat/Front fender Rear fender Battery cover Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. 1 1 ECA4D3F001 3 Battery lead 2 4 5 6 7 8 9 10 Battery Relay CDI unit Tail/brake light lead Air filter case breather hose Clamp Air filter case 1 2 1 1 1 1 1 First disconnect the negative lead, then disconnect the positive lead. Disconnect. Disconnect. Loosen. For installation, reverse the removal procedure.
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheels and brake discs Order 1 2 3 4 5 6 7 Job/Parts to remove Q’ty Cotter pin Axle nut Front wheel Brake disc guard (outer) Brake caliper assembly Wheel hub Brake disc Remarks The following procedure applies to both of the front wheels. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
FRONT WHEEL EAS21890 REMOVING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. TIP Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • Front wheel EAS29380 CHECKING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1.
FRONT WHEEL EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1. Install: • Bearings “1” TIP Face the oil seal side of the bearing inward. 2. Check: • Wheel bearings Wheel hub play/wheel turns roughly → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Clean wheel hub exterior. b. Drive bearing out by pushing spacer aside and tapping around perimeter of bearing inner race. Use soft metal drift punch and hammer. The spacer “1” “floats” between bearings. Remove both bearings asdescribed.
FRONT WHEEL f. Repeat steps (d) through (f) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheel’s heavy spot “X”. EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire, wheel or both, the front wheel static balance should be adjusted. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Adjust: • Front wheel static balance 1. Remove: • Balancing weight(s) 2.
FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS29420 INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1. Install: • Brake disc guard (outer) “1” TIP Install the brake disc guard (outer) with punched burrs “2” on the wheel hub side. 2.
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheels Order 1 2 3 4 Job/Parts to remove Q’ty 2 2 2 2 Rear wheel Cotter pin Axle nut Wheel hub Remarks For installation, reverse the removal procedure.
REAR WHEEL EAS22040 REMOVING THE REAR WHEELS 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. TIP Place the vehicle on a suitable stand so that the rear wheel is elevated. EAS29450 2. Remove: • Rear wheels INSTALLING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs. 1.
REAR AXLE AND REAR AXLE HUB EAS29470 REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub Order 1 2 3 Job/Parts to remove Rear wheels/Rear wheel hubs Rear axle ring nut set bolt Rear axle ring nut Conical spring washer Q’ty Remarks Refer to “REAR WHEEL” on page 4-9.
REAR AXLE AND REAR AXLE HUB Removing the rear axle and rear axle hub Order 14 Job/Parts to remove Q’ty 2 Dust cover Remarks For installation, reverse the removal procedure.
REAR AXLE AND REAR AXLE HUB • Attach a suitable socket “2” on the axle end and tap it with a soft hammer, then pull out the rear axle to the right. EAS29490 REMOVING THE REAR AXLE 1. Place the vehicle on a level surface. 2. Loosen: • Rear axle ring nut set bolts “1” 3. Remove: • Rear axle ring nut “2” TIP • Apply the brake pedal so that the rear axle does not turn when loosening the nut. • Use the PTT wrench 46 or axle nut wrench (46 mm) “3”.
REAR AXLE AND REAR AXLE HUB EAS29510 CHECKING THE REAR WHEEL SPROCKET 1. Check: • Rear wheel sprocket Refer to “CHECKING THE DRIVE SPROCKET” on page 4-59. Rear axle ring nut 140 Nm (14.0 m·kg, 103 ft·lbf) LOCTITE® Rear axle ring nut set bolt 7 Nm (0.7 m·kg, 5.2 ft·lbf) LOCTITE® EAS4D3F029 CHECKING THE SPROCKET BRACKET 1. Check: • Sprocket bracket Cracks/damage → Replace. TIP • Apply the brake pedal so that the rear axle does not turn when tightening the nut.
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order 1 2 3 4 Job/Parts to remove Q’ty Front wheel Bolt Brake pad retaining bolt Brake pad Brake pad spring Remarks The following procedure applies to both of the front brake calipers. Refer to “FRONT WHEEL” on page 4-4. 1 1 2 1 For installation, reverse the removal procedure.
FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Brake fluid 1 2 3 4 5 6 7 8 9 10 Brake fluid reservoir cap Brake fluid reservoir diaphragm plate Brake fluid reservoir diaphragm Front brake light switch Brake lever Union bolt Copper washer Brake hose Brake master cylinder bracket Brake master cylinder 1 1 1 1 1 1 2 1 1 1 Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Disconnect. For installation, reverse the removal procedure.
FRONT BRAKE Disassembling the front brake master cylinder Order 1 2 Job/Parts to remove Brake master cylinder kit Brake master cylinder body Q’ty 1 1 Remarks For assembly, reverse the disassembly procedure.
FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Brake fluid 1 2 3 4 5 6 Front wheel Union bolt Copper washer Brake hose Bolt Brake pad retaining bolt Brake caliper assembly 1 2 1 1 1 1 Remarks The following procedure applies to both of the front brake calipers. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Refer to “FRONT WHEEL” on page 4-4. Disconnect. Loosen. For installation, reverse the removal procedure.
FRONT BRAKE Disassembling the front brake calipers Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Q’ty Bolt Brake pad retaining bolt Brake pad Brake pad spring Caliper bracket Caliper piston Dust seal Caliper piston seal Bleed screw Remarks The following procedure applies to both of the front brake calipers. 1 1 2 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT BRAKE EAS22220 INTRODUCTION Brake disc thickness limit 3.0 mm (0.12 in) EWA14100 WARNING Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components.
FRONT BRAKE b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. EAS22250 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. TIP Bleed screw 5 Nm (0.5 m·kg, 3.7 ft·lb) When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. d. Install new brake pads and a new brake pad spring. 1.
FRONT BRAKE TIP Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Union bolt “1” • Copper washers “2” • Brake hose “3” • Brake caliper bolts “4” b. Remove the brake caliper piston seal and brake caliper dust seal.
FRONT BRAKE EWA4D3F006 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seal and brake caliper dust seal. 2. Check: • Brake caliper bracket “1” Cracks/damage → Replace. EAS22420 INSTALLING THE FRONT BRAKE CALIPER 1. Install: • Brake caliper “1” (temporarily) • Copper washers “2” New • Brake hose “3” • Union bolt “4” EAS22400 ASSEMBLING THE FRONT BRAKE CALIPER Brake hose union bolt 27 Nm (2.
FRONT BRAKE Brake pad retaining bolt 17 Nm (1.7 m·kg, 13 ft·lb) Brake caliper bolt 28 Nm (2.8 m·kg, 21 ft·lb) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-21. 4. Fill: • Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) 7. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Recommended fluid DOT 4 EWA13090 WARNING • Use only the designated brake fluid.
FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” Brake master cylinder bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) TIP • Install the brake master cylinder holder with the “UP” mark facing up. • Install the brake master cylinder so that the gaps between the brake master cylinder and the brake master cylinder bracket are equal. 2. Check: • Brake master cylinder kit “1” Damage/scratches/wear → Replace. 3.
FRONT BRAKE 3. Fill: • Brake master cylinder reservoir (with the specified amount of the recommended brake fluid) 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Recommended fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order 1 2 3 4 Job/Parts to remove Brake pad retaining bolt Lock washer Brake pad Brake pad spring Q’ty 2 1 2 1 Remarks For installation, reverse the removal procedure.
REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Right foot protector Q’ty Brake fluid 1 2 3 4 5 6 7 8 9 10 11 12 13 Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Union bolt Copper washer Brake hose Brake master cylinder Rear brake light switch Right footrest Brake pedal/spring Remarks Refer to “GENERAL CHASSIS” on page 4-1. Drain.
REAR BRAKE Disassembling the rear brake master cylinder Order 1 2 3 Job/Parts to remove Hose joint Brake master cylinder kit Brake master cylinder Q’ty 1 1 1 Remarks For assembly, reverse the disassembly procedure.
REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Brake fluid 1 2 3 4 5 Parking brake cable Union bolt Copper washer Brake hose Brake caliper assembly 1 1 2 1 1 Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. Disconnect. For installation, reverse the removal procedure.
REAR BRAKE Disassembling the rear brake calipers Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Parts to remove Adjusting bolt Locknut Parking brake arm Brake pad retaining bolt Lock washer Brake pad Brake pad spring Retaining bolt Caliper bracket Brake caliper piston Dust seal Caliper piston seal Bleed screw Q’ty 1 1 1 2 1 2 1 1 1 1 1 1 1 Remarks For assembly, reverse the disassembly procedure.
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit 3.5 mm (0.14 in) EWA14100 WARNING 5. Adjust: • Brake disc deflection Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-20. Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary.
REAR BRAKE 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-17. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 5 Nm (0.5 m·kg, 3.7 ft·lb) 7. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-20. d.
REAR BRAKE 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. • Brake caliper cylinder “2” Scratches/wear → Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EAS22600 DISASSEMBLING THE REAR BRAKE CALIPER 1.
REAR BRAKE 1. Install: Brake hose union bolt 31 Nm (3.1 m·kg, 23 ft·lb) • O-ring “1” New • Caliper piston seal “2” New EWA13530 • Caliper dust seal “3” New WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-29. ECA14170 When installing the brake hose onto the brake caliper “1”, make sure the brake pipe touches the projection “a” on the brake caliper. 2. Install: • Brake caliper piston “1” 3. Install: • Parking brake arm “1” 4.
REAR BRAKE EWA13090 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake fluid reservoir.
REAR BRAKE Clearance 2.2–3.2 mm (0.09–0.13 in) 3. Check: • Brake fluid reservoir “1” Cracks/damage → Replace. • Brake fluid reservoir diaphragm “2” Cracks/damage → Replace. EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washers New • Brake hose “1” • Union bolt “2” Brake hose union bolt 31 Nm (3.1 m·kg, 23 ft·lb) EWA13530 4. Check: • Brake hoses Cracks/damage/wear → Replace. WARNING Proper brake hose routing is essential to insure safe vehicle operation.
REAR BRAKE 3. Fill: • Brake fluid reservoir (with the specified amount of the recommended brake fluid) 6. Adjust: • Brake pedal position Refer to “ADJUSTING THE BRAKE PEDAL” on page 3-16. Recommended fluid DOT 4 Brake pedal height 40.0 mm (1.57 in) EWA13090 WARNING 7. Adjust: • Rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-19. • Use only the designated brake fluid.
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Parts to remove Handlebar protector Band Front brake light switch Brake master cylinder/bracket Throttle lever assembly/bracket Spacer Clutch switch Parking brake lever Clutch lever/bracket Handlebar switch Handlebar grip Handlebar holder Handlebar Q’ty 1 3 1 1/1 1/1 1 1 1 1/1 1 2 2 1 Remarks For installation, reverse the removal procedure.
HANDLEBAR EAS22860 EAS22911 REMOVING THE HANDLEBARS 1. Remove: • Clutch switch “1” INSTALLING THE HANDLEBAR 1. Install: • Handlebar • Upper handlebar holders TIP Push the fastener when removing the clutch switch out of the clutch lever holder. Upper handlebar holder bolt 20 Nm (2.0 m·kg, 15 ft·lb) TIP • Install the handlebar horizontally shown in the illustration. • The upper handlebar holder should be installed with the punched mark “1” forward “2”. ECA4D3F004 2.
HANDLEBAR 4. Install: • Throttle lever assembly • Spacer • Brake master cylinder TIP • Before applying the adhesive, wipe off grease or oil on the handlebar surface “a” with a lacquer thinner. • Install the handlebar grips so that the “L” arrow on the left grip and “R” arrow on the right grip are placed vertically. Brake master cylinder bracket bolt 7 Nm (0.7 m·kg, 5.2 ft·lb) TIP • Engage the indentations “a” in the spacer with the lobes “b” on the throttle lever assembly and brake master cylinder.
HANDLEBAR Throttle cable free play 2.0–4.0 mm (0.08–0.
STEERING STEM EAS29540 STEERING STEM Removing the steering stem Order 1 2 3 4 5 6 7 Job/Parts to remove Front fender Lock washer Bracket Steering stem bushing Spacer Oil seal Steering stem Bushing Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. 1 1 2 2 2 1 2 For installation, reverse the removal procedure.
STEERING STEM EAS29560 EAS29580 CHECKING THE STEERING STEM 1. Check: • Steering stem “1” Bends → Replace. INSTALLING THE LOCK WASHER 1. Install: • Lock washer “1” New • Steering stem bushing bolts EWA15030 WARNING Steering stem bushing bolt 23 Nm (2.3 m·kg, 17 ft·lb) Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Bend the lock washer tabs along a flat side of the bolts. 2. Check: • Oil seals “1” New • Steering stem bushings “2” Wear/damage → Replace. 3.
TIE-RODS AND STEERING KNUCKLES EAS29660 TIE-RODS AND STEERING KNUCKLES Removing the tie-rods and steering knuckles Order 1 2 3 4 5 6 Job/Parts to remove Q’ty Front wheel Front brake caliper/Brake disc Brake disc guard (inner) Tie-rod Front bumper Lower front arm Upper front arm Steering knuckle Remarks The following procedure applies to both of the tie-rods and steering knuckles. Refer to “FRONT WHEEL” on page 4-4. Refer to “FRONT BRAKE” on page 4-15.
TIE-RODS AND STEERING KNUCKLES EAS29670 REMOVING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles. 1. Remove: • Steering knuckle “1” TIP Use a general puller to separate the ball joints “2” from the steering knuckle “1”. EAS29700 INSTALLING THE TIE-RODS The following procedure applies to both of the tie-rods. 1. Install: • Tie-rod Tie-rod nut 25 Nm (2.5 m·kg, 18 ft·lb) TIP Install the tie-rod so that the groove “1” is on the wheel side.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29710 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES Removing the front arms and front shock absorber assemblies Order 1 2 3 4 5 6 7 8 9 10 11 Job/Parts to remove Q’ty Front wheel Front brake caliper/Brake disc Front bumper Brake disc guard (inner) Tie-rod Lower front arm Upper front arm Front shock absorber assembly Steering knuckle Dust cover Spacer Spacer Bushing 1 1 1 1 1 1 1 6 1 2 6 Remarks The following procedure applies to both of the front up
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29720 REMOVING THE FRONT ARMS The following procedure applies to both of the front upper arms and front lower arms. 1. Check: • Front arm free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the front arm side play “A” by moving it from side to side. If side play is noticeable, check the bushings.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES EAS29770 CHECKING THE FRONT ARM BALL JOINTS The following procedure applies to each of the front arm ball joints. 1. Check: • Ball joint Damage/pitting → Replace the front arm. Free play → Replace the front arm. Turns roughly → Replace the front arm. EAS29760 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies. 1.
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES TIP Apply lithium-soap-based grease to the grease nipples “3”. Front upper arm nut 45 Nm (4.5 m·kg, 33 ft·lb) Front lower arm nut 45 Nm (4.
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Seat/Rear fender/Air filter case Q’ty 1 Clamp 2 2 Rear shock absorber assembly 1 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Loosen. For 4D3H, 4D3M For installation, reverse the removal procedure.
REAR SHOCK ABSORBER ASSEMBLY EAS23170 HANDLING THE REAR SHOCK ABSORBER EWA13750 WARNING This rear shock absorber and gas cylinder contains highly compressed nitrogen gas. Before handling the rear shock absorber and gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder.
REAR SHOCK ABSORBER ASSEMBLY A. for 4D3D B. for 4D3H, 4D3M EAS23300 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: • Rear shock absorber assembly TIP When installing the rear shock absorber assembly lower bolt, lift up the swingarm. Rear shock absorber assembly nut 55 Nm (5.
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Rear axle hub Rear shock absorber assembly 1 2 3 4 5 6 7 8 9 Plate Swingarm end cover Pivot shaft nut/washer Pivot shaft Swingarm Drive chain guide 1 Dust cover/oil seal Spacer Bearing Remarks Refer to “REAR AXLE AND REAR AXLE HUB” on page 4-11. Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-51. 1 1 1/1 1 1 1 2/2 1 2 For installation, reverse the removal procedure.
SWINGARM EAS23340 EAS23360 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. CHECKING THE SWINGARM 1. Check: • Swingarm Bends/cracks/damage → Replace. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. TIP Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Measure: • Swingarm side play • Swingarm vertical movement 2. Check: • Pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace.
SWINGARM EAS23380 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacer • Oil seals Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” • Spacer “2” • Oil seals • Dust covers TIP Inject the bearing with the character stamp turned outward. Installed depth of bearing “a” 1–2 mm (0.04–0.08 in) 3. Install: • Pivot shaft Pivot shaft nut 100 Nm (10.0 m·kg, 74 ft·lb) 4.
CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order 1 2 3 4 5 6 7 Job/Parts to remove Drive sprocket cover Drive chain guide 2 Drive chain guide 3 Drive sprocket nut Lock washer Drive sprocket Drive chain Q’ty 1 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
CHAIN DRIVE b. Calculate the length “c” of the 15-link section of the drive chain using the following formula. Drive chain 15-link section length “c” = (length “a” between pin inner sides + length “b” between pin outer sides)/2 EAS23430 REMOVING THE DRIVE CHAIN 1. Remove: • Master link clip (with interlocking slip-joint pliers) 2. Remove: • Master link plate “1” • O-ring “2” • Master link “3” TIP • When measuring a 15-link section of the drive chain, make sure that the drive chain is taut.
CHAIN DRIVE EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. b. Correct 1. Drive chain roller 2. Drive chain sprocket ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING THE DRIVE SPROCKET” on page 4-59. 3. Check: • O-rings “1” Damage → Replace the drive chain.
CHAIN DRIVE 6. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-21. Drive chain slack 45–55 mm (1.77–2.17 in) ECA13550 A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 3. Bend the lock washer tab along a flat side of the nut. 4.
CHAIN DRIVE 4-61
ENGINE ENGINE REMOVAL ......................................................................................5-1 INSTALLING THE ENGINE ....................................................................5-4 INSTALLING THE MUFFLER AND EXHAUST PIPE..............................5-4 CAMSHAFT ..................................................................................................5-6 REMOVING THE ROCKER ARMS AND CAMSHAFT ...........................5-7 CHECKING THE CAMSHAFT ...............................
ASSENBLING THE BALANCER WEIGHT GEAR................................5-41 INSTALLING THE OIL PUMP ...............................................................5-41 INSTALLING THE BALANCER WEIGHT GEAR ..................................5-41 SHIFT SHAFT .............................................................................................5-42 CHECKING THE SHIFT SHAFT ..........................................................5-43 CHECKING THE STOPPER LEVER.................................................
ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the muffler and exhaust pipe Order 1 2 3 4 5 6 Job/Parts to remove Seat/front panel/front fender/rear fender Clamp Muffler Gasket Exhaust pipe EXhaust pipe protector Gasket Q’ty 1 1 1 1 1 1 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Loosen. For installation, reverse the removal procedure.
ENGINE REMOVAL Disconnecting the leads, cables and hoses Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Engine oil Oil cooler hose 1, 2 Carburetor Drive sprocket/drive chain Ignition coil spark plug lead Air filter case breather hose Starter motor lead Battery negative lead Clutch cable Plastic band Parking brake cable AC magneto coupler Neutral switch connector Q’ty 1 1 1 1 1 1 1 2 1 5-2 Remarks Drain. Refer to “CLUTCH” on page 5-29. Refer to “CARBURETOR” on page 6-3.
ENGINE REMOVAL Removing the engine Order 1 2 3 4 5 6 7 8 Job/Parts to remove Crankcase bolt Engine mounting bolt (front) Engine bracket (left and right) Engine mounting bolt (upper) Engine bracket (upper) Engine mounting bolt (rear upper) Engine mounting bolt (rear lower) Engine assembly Q’ty 1 1 2 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine mounting bolt (rear lower side) “1” • Engine mounting bolt (rear upper side) “2” • Engine bracket bolts (upper side) “3” • Engine mounting bolt (upper side) “4” • Engine brackets (front side) “5” “6” • Engine mounting bolt (front side) “7” TIP • The direction of the bolt insertion is made from the right side of the body. • Do not fully tighten the bolts. 2. Install: • Crankcase bolt “8” 3.
ENGINE REMOVAL 4. Install: • Gasket New • Exhaust pipe “1” 5. Tighten: • Nuts (exhaust pipe) “2” Exhaust pipe nut 18 Nm (1.8 m·kg, 13 ft·lb) 6. Install: • Clamp TIP Slide the clamp onto the end of the muffler and insert the projection “a” of the clamp into a slot “b” in the muffler. Tighten the clamp after installing the muffler.
CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft Order 1 2 3 4 5 6 7 Job/Parts to remove Cylinder head Lock plate Locknut/valve clearance adjusting screw Camshaft Intake rocker arm shaft Intake rocker arm Exhaust rocker arm shaft Exhaust rocker arm Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-10. 1 2/2 1 1 1 1 1 For installation, reverse the removal procedure.
CAMSHAFT EAS23770 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • Locknut “1” • Valve clearance adjusting screw “2” 2. Remove: • Lock plate “3” EAS23840 CHECKING THE CAMSHAFT 1. Check: • Bearing Damage/wear → Replace. 2. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 3. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification → Replace the camshaft. 3. Remove: • Camshaft “1” • Bearing “2” TIP Screw 10 mm (0.
CAMSHAFT 2. Check: • Rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3. Measure: • Rocker arm inside diameter “a” Out of specification → Replace. Rocker arm inside diameter 12.000–12.018 mm (0.4724– 0.4731 in) Limit 12.036 mm (0.4739 in) 4. Check: • Camshaft oil passage Obstruction → Blow out with compressed air. 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diameter 11.981–11.
CAMSHAFT Out of specification → Replace the defective part(s). • Install the intake rocker arm shaft so that groove “a” is horizontal and aligning the notch of the pointed end “b” with the hole in the cylinder head. Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.037 mm (0.0004– 0.0015 in) EAS24040 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • Camshaft Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil 2.
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Job/Parts to remove Seat/front panel/front fender Fuel tank/fuel tank shield Muffler and exhaust pipe/Ignition coil spark plug lead/Engine bracket (upper side) Carburetor Spark plug Cylinder head cover 1/O-ring Cylinder head cover 2/O-ring Cylinder head cover 3/O-ring Breather plate 1/Gasket Crankshaft end accessing screw/O-ring Timing mark accessing screw/O-ring Camshaft sprocket bolt Cap bolt T
CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty 5-11 Remarks For installation, reverse the removal procedure.
CYLINDER HEAD Breather plate 2 • Camshaft sprocket • Timing chain EAS24130 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark “a” on the pickup coil rotor (with the stationary pointer “b” on the crankcase cover) TIP To prevent the timing chain from falling into the crankcase, fasten it with a wire. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Remove: • Cylinder head “1” a. Turn the pickup coil rotor counterclockwise. b.
CYLINDER HEAD 2. Check: • Cylinder head Damage/scratches → Replace. 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. b. Correct 1. Timing chain 2. Camshaft sprocket 2. Check: • Timing chain guide (exhaust side) Damage/wear → Replace the defective part(s). Warpage limit 0.05 mm (0.0020 in) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. EAS24200 CHECKING THE TIMING CHAIN TENSIONER 1.
CYLINDER HEAD 3. Check: • Cap bolt • Spring • One-way cam • Timing chain tensioner rod Damage/wear → Replace the timing chain tensioner. EAS24230 INSTALLING THE CYLINDER HEAD 1. Install: • Cylinder head gasket New • Dowel pins 2. Install: • Cylinder head c. Remove the wire from the timing chain. d. Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto the camshaft. • Copper washers New • Cylinder head bolts 3.
CYLINDER HEAD b. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the new gasket and the timing chain tensioner “2” onto the body cylinder. c. Tighten the timing chain tensioner bolts “3” to the specified torque. Camshaft sprocket bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt “4” to the specified torque. 8.
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order 1 2 3 4 5 6 7 8 9 Job/Parts to remove Cylinder head Rocker arm/camshaft Valve cotter Valve spring retainer Outer valve spring Inner valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat Valve guide Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-10. Refer to “CAMSHAFT” on page 5-6. 4 2 2 2 1 1 2 2 2 For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. TIP Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • Valve sealing Leakage at the valve seat → Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS” on page 5-19. 3.
VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004– 0.0015 in) Limit 0.080 mm (0.003 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010– 0.0020 in) Limit 0.100 mm (0.004 in) b. Install the new valve guide with the valve guide installer “2” and valve guide remover “1”. c.
VALVES AND VALVE SPRINGS TIP Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066 • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm (0.0004 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3.
VALVES AND VALVE SPRINGS ECA13790 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. Do not let the lapping compound enter the gap between the valve stem and the valve guide. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d. Measure the valve seat width. b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d.
VALVES AND VALVE SPRINGS a. Compressed valve spring force b. Installed length ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Inner spring Installed compression spring force (intake) 75.00–91.70 N (7.65–9.35 kgf, 16.86–20.61 lbf) Installed compression spring force (exhaust) 75.00–91.70 N (7.65–9.35 kgf, 16.86–20.
VALVES AND VALVE SPRINGS • Outer valve spring “5” • Upper spring seat “6” (into the cylinder head) Inner spring Spring tilt (intake) 2.5 °/1.60 mm (2.5 °/0.063 in) Spring tilt (exhaust) 2.5 °/1.60 mm (2.5 °/0.063 in) Outer spring Spring tilt (intake) 2.5 °/1.60 mm (2.5 °/0.063 in) Spring tilt (exhaust) 2.5 °/1.60 mm (2.5 °/0.063 in) TIP Install the valve springs with the larger pitch “a” facing up.
VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a softface hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve.
CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston Order 1 2 3 4 5 6 7 8 Job/Parts to remove Cylinder head Oil delivery pipe Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Piston ring set Q’ty Remarks Refer to “CYLINDER HEAD” on page 5-10. 1 1 2 1 2 1 1 1 For installation, reverse the removal procedure.
CYLINDER AND PISTON EAS24380 TIP REMOVING THE PISTON 1. Remove: • Piston pin clips “1” • Piston pin “2” • Piston “3” When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. ECA13810 Do not use a hammer to drive the piston pin out. TIP • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
CYLINDER AND PISTON b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter D “a” with the micrometer. Piston ring Top ring Ring side clearance 0.030–0.065 mm (0.0012– 0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008– 0.0022 in) Limit 0.115 mm (0.0045 in) Piston size diameter “D” Standard 73.983–73.998 mm (2.9127– 2.9133 in) b. 5 mm (0.
CYLINDER AND PISTON Piston ring Top ring End gap (installed) 0.19–0.31 mm (0.007–0.012 in) Limit 0.56 mm (0.022 in) 2nd ring End gap (installed) 0.30–0.45 mm (0.012–0.018 in) Limit 0.80 mm (0.032 in) Oil ring End gap (installed) 0.10–0.35 mm (0.004–0.014 in) 3. Measure: • Piston pin bore diameter “b” Out of specification → Replace the piston. Piston pin bore inside diameter 17.002–17.013 mm (0.6694– 0.6698 in) Limit 17.043 mm (0.6710 in) a. 40 mm (1.476 in) EAS24440 CHECKING THE PISTON PIN 1.
CYLINDER AND PISTON 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) • Upper oil ring rail “3” • 2nd ring “4” • Top ring “5” TIP Be sure to install the piston rings so that the “T” marks or numbers face up. Recommended lubricant Engine oil 5. Offset: • Piston ring end gaps a. b. c. d. e. f. 2. Install: • Piston “1” • Piston pin “2” Top ring Upper oil ring rail Oil ring expander Lower oil ring rail 2nd ring 20 mm 6.
CLUTCH EAS25061 CLUTCH Removing the clutch cover Order Job/Parts to remove Q’ty Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-10. Engine oil 1 2 3 4 5 6 7 8 9 Remarks Cotter pin/Washer Clevis pin Brake pedal/Footrest Oil delivery pipe Oil cooler hose O-ring Right crankcase cover Dowel pin Crankcase cover gasket 1/1 1 1/1 1 2 2 1 2 1 For installation, reverse the removal procedure.
CLUTCH Removing the clutch Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Job/Parts to remove Clutch spring Pressure plate Primary drive gear nut Friction plate Clutch plate Clutch boss nut Clutch boss Thrust washer Clutch housing Claw washer Primary drive gear Locknut/Washer Push rod 1 Push plate Push rod 2/Ball Q’ty 5 1 1 6 5 1 1 1 1 1 1 1/1 1 1 1/1 Remarks For installation, reverse the removal procedure.
CLUTCH Removing the push lever shaft Order Job/Parts to remove Q’ty Shift pedal Left crankcase cover 1 2 3 4 5 6 7 Clutch assembly Clutch cable Bolt Push lever shaft Torsion spring Circlip Oil seal Bearing Remarks Refer to “SHIFT SHAFT” on page 5-42. Refer to “PICKUP COIL ROTOR AND STARTER CLUTCH” on page 5-45. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Bolt “1” • Clutch spring “2” TIP Loosen the bolts in stages and in a crisscross pattern. 4. Remove: • Clutch boss nut “1” • Lock washer “2” • Clutch boss “3” • Thrust washer “4” • Clutch housing “5” 2. Straighten the lock washer tab. 3. Loosen: • Primary drive gear nut • Clutch boss nut TIP • Place the aluminum plate “a” between clutch housing “1” and primary drive gear “2”, and then loosen the primary drive gear nut “3”.
CLUTCH EAS25140 TIP CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • Clutch spring Damage → Replace the clutch springs as a set. 2. Measure: • Clutch spring free length “a” Out of specification → Replace the clutch springs as a set. Measure the friction plate at four places. Friction plate thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.80 mm (0.110 in) Clutch spring free length 47.80 mm (1.88 in) Minimum length 46.50 mm (1.
CLUTCH EAS25260 TIP INSTALLING THE CLUTCH 1. Install: • Primary drive gear • Claw washer Pitting on the clutch boss splines will cause erratic clutch operation. • Lock washer New • Primary drive gear nut 2. Install: • Clutch housing • Thrust washer • Clutch boss • Lock washer “1” New • Clutch boss nut TIP Make sure the teeth on the lock washer are correctly aligned with the grooves on the clutch boss. EAS25170 CHECKING THE PRESSURE PLATE 1. Check: • Pressure plate Cracks/damage → Replace.
CLUTCH TIP After installing the clutch cable, bend the push lever shaft tab along a flat side of the nut. 8. Install: • Push rod 2 • Ball • Push rod 1 • Push plate • Washer • Locknut • Pressure plate • Clutch spring “1” • Bolt “2” 9. Tighten: • Clutch spring bolt • Locknut Clutch spring bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Locknut 8 Nm (0.8 m·kg, 5.8 ft·lb) 4. Bend the lock washer tab along a flat side of the nut. 5.
CLUTCH 13. Install: • Clamp • Dowel pin • Crankcase cover gasket New 11. Adjust: • Push lever position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut “1”. b. Turn the adjusting screw “2” in or out until the marks are aligned. c. Hold the adjusting screw to prevent it from moving and then tighten the locknut to specification. ECA13820 Do not overtighten the locknut since this will remove the free play between both push rods. Locknut 8 Nm (0.8 m·kg, 5.9 ft·lb) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 12.
CLUTCH 14. Install: • Right crankcase cover 15. Install: • Crankcase cover bolts M6 × 50 mm “1”, “2” • Copper washers to “1”, “2” • Crankcase cover bolts M6 × 40 mm “3”– “6” • Crankcase cover bolts M6 × 25 mm “7”– “13” • Oil filter element cover bolt M6 × 70 mm “14” 16. Tighten: • Crankcase cover bolts “1”–“13” • Oil filter element cover bolt “14” TIP Tighten the bolts in stages, using a crisscross pattern. Crankcase cover bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) Oil filter element cover bolt 10 Nm (1.0 m·kg, 7.
OIL PUMP EAS24911 OIL PUMP Removing the oil pump Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Job/Parts to remove Right crankcase cover /clutch /primary drive gear Balancer weight gear nut Lock washer Buffer boss Balancer weight gear Absorber plate Compression spring Dowel pin Straight key Spacer Circlip Oil pump driven gear Oil pump assembly Gasket Balancer drive gear Oil strainer Spacer Q’ty Remarks Refer to “CLUTCH” on page 5-29.
OIL PUMP Disassemble the oil pump Order 1 2 3 4 5 6 7 Job/Parts to remove Oil pump housing Dowel pin Outer rotor Inner rotor Dowel pin Shaft Oil pump cover Q’ty 1 2 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
OIL PUMP EAS24940 REMOVING THE OIL PUMP 1. Straighten the lock washer tab. 2. Remove: • Balancer weight gear nut • Lock washer • Balancer weight gear Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.0059 in) Limit 0.23 mm (0.0091 in) Outer-rotor-to-oil-pump-housing clearance 0.100–0.151 mm (0.0039– 0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-andouter-rotor clearance 0.04–0.09 mm (0.0016–0.0035 in) Limit 0.16 mm (0.
OIL PUMP • Compression spring • Dowel pin Cracks/damage/wear → Replace. TIP • Align the punch mark “a” in the balancer drive gear with the punch mark “b” in the balancer weight gear • Place the aluminium plate “c” between balancer drive gear “1” and balancer weight gear “2”, and then tighten the balancer weight gear nut “3”. EAS4D3F018 ASSENBLING THE BALANCER WEIGHT GEAR 1. Assemble: • Dowel pin “1” • Compression spring “2” TIP Install the dowel pins and compression springs alternately as shown as. 2.
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order 1 2 3 4 Job/Parts to remove Right crankcase cover/clutch Shift pedal Shift shaft assembly Stopper lever Torsion spring Q’ty Remarks Refer to “CLUTCH” on page 5-29. 1 1 1 1 For installation, reverse the removal procedure.
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” • Shift lever “2” Bends/damage/wear → Replace. • Shift lever spring Damage/wear → Replace. 2. Tighten: • Stopper lever bolt Stopper lever bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) LOCTITE® EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. • Torsion spring Damage/wear → Replace. 3.
SHIFT SHAFT 6. Tighten: • Shift pedal bolt Shift pedal bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) 7. Adjust: • Shift pedal height Refer to “ADJUSTING THE SHIFT PEDAL” on page 3-21.
PICKUP COIL ROTOR AND STARTER CLUTCH EAS403F008 PICKUP COIL ROTOR AND STARTER CLUTCH Removing the pickup coil rotor and starter clutch Order Job/Parts to remove Q’ty Drain. Refer to “ENGINE” on page 3-4. Refer to “SHIFT SHAFT” on page 5-42. Refer to “CHAIN DRIVE” on page 4-57.
PICKUP COIL ROTOR AND STARTER CLUTCH EAS403F009 REMOVING THE PICKUPCOIL ROTOR 1. Remove: • Pickup coil rotor bolt “1” • Washer TIP • Loosen the pickup coil rotor bolt “1” while holding the rotor with a sheave holder “2”. • Do not allow the sheave holder to touch the projection on the rotor “a”. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 4. Remove: • Starter idle gear 2 “1” • Starter wheel gear “2” • Bearing “3” • Washer “4” 2.
PICKUP COIL ROTOR AND STARTER CLUTCH 3. Check: • Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: • Starter clutch operation 2. Install: • Woodruff key “1” • Pickup coil rotor “2” • Washer “3” • pickup coil rotor bolt “4” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ TIP a. Install the starter wheel gear “1” onto the starter clutch “2” and hold the starter clutch. b.
PICKUP COIL ROTOR AND STARTER CLUTCH Crank case cover bolt M6 × 30 mm: “1”–“5” 10 Nm (1.0 m·kg, 7.4 ft·lb) M6 × 45 mm: “6” 10 Nm (1.0 m·kg, 7.4 ft·lb) M6 × 40 mm: “7”–“9” 10 Nm (1.0 m·kg, 7.4 ft·lb) 4. Install: • Stator coil “1” • Pickup coil “2” 5. Tighten: • Stator coil bolts “3” • Pickup coil bolts “4” • Left crankcase cover bolt “5” Stator coil bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) LOCTITE® Pickup coil bolt 10 Nm (1.0 m·kg, 7.4 ft·lb) LOCTITE® Left crankcase cover bolt 7 Nm (0.7 m·kg, 5.
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Exhaust pipe Starter idle gear cover/Starter idle gear 1 2 3 Clutch cable holder Starter motor lead Starter motor 1 1 1 Remarks Refer to “ENGINE REMOVAL” on page 5-1. Refer to “PICKUP COIL ROTOR AND STARTER CLUTCH” on page 5-45. Disconnect. For installation, reverse the removal procedure.
ELECTRIC STARTER Disassembling the starter motor Order 1 2 3 4 5 6 7 8 Job/Parts to remove Front bracket Tang washer Plate washer Circlip Rear bracket/Brush holder Armature assembly Starter motor yoke Brush/spring Q’ty 1 1 1 1 1/1 1 1 2/2 Remarks For assembly, reverse the disassembly procedure.
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter “a” Out of specification → Replace the starter motor. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coil Commutator resistance “1” 0.013–0.015 Ω at 20 °C (68 °F) Insulation resistance “2” Above 1 MΩ at 20 °C (68 °F) Commutator wear limit 21 mm (0.83 in) b. If any resistance is out of specification, replace the starter motor. 3.
ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bushing • Bearing • Oil seal Damage/wear → Replace the defective part(s). 4. Install: • Starter motor yoke “1” TIP Align the match marks “a” on the starter yoke “1” with the match marks “b” on the rear bracket. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush spring “1” • Brush “2” 5. Install: • Tang washer “1” • Plate washer “2” • Front bracket “3” 2.
CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Engine Cylinder head Q’ty Cylinder/piston Clutch Oil pump/balancer weight gear Shift shaft Pickup coil rotor 1 2 3 4 5 6 7 Timing chain guide (intake side) Timing chain Crankshaft sprocket Right crankcase Dowel pin Left crankcase Spacer Remarks Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CYLINDER HEAD” on page 5-10. Refer to “CYLINDER AND PISTON” on page 5-24. Refer to “CLUTCH” on page 5-29.
CRANKCASE Removing the bearing Order Job/Parts to remove Q’ty Crankshaft assembly 1 2 Main axle assembly/drive axle assembly Oil seal Bearing Remarks Refer to “CRANKSHAFT ASSEMBLY” on page 5-57. Refer to “TRANSMISSION” on page 5-61. 2 8 For assembly, reverse the removal procedure.
CRANKCASE EAS25570 DISASSEMBLING THE CRANKCASE 1. Remove: • Timing chain guide (intake side) “1” • Timing chain “2” • Crankshaft sprocket “3” 4. Remove: • Right crankcase ECA13910 • First check that the shift drum segment’s teeth and the drive axle circlip are properly positioned, then remove the right crankcase. • Do not damage the crankcase mating surfaces. 2.
CRANKCASE Timing chain guide (intake side) bolt 8 Nm (0.8 m·kg, 5.9 ft·lb) LOCTITE® 3. Install: • Right crankcase (onto the left crankcase) TIP Tap lightly on the right crankcase with a softface hammer. 9. Apply: • Engine oil (onto the crankshaft pins bearings and oil delivery holes) 10. Check: • Crankshaft and transmission operation Rough movement → Repair. 4. Install: • Crankcase bolt M6 × 70 mm: “1”–“3” • Copper washers To “1”–“3”.
CRANKSHAFT ASSEMBLY EAS25970 CRANKSHAFT ASSEMBLY Removing the crankshaft assembly Order 1 2 3 4 5 Job/Parts to remove Crankcase Balancer weight Crankshaft assembly Dowel pin Plunger seal Bearing Q’ty Remarks Refer to “CRANKCASE” on page 5-53. 1 1 1 1 1 For installation, reverse the removal procedure.
CRANKSHAFT ASSEMBLY EAS25990 EAS26060 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • Balancer weight • Crankshaft assembly “1” CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • Crankshaft runout Out of specification → Replace the crankshaft, bearing or both. TIP • Remove the crankshaft assembly with the crankcase separating tool “2”. • Make sure the crankcase separating tool is centered over the crankshaft assembly. TIP Turn the crankshaft slowly. Runout limit C 0.03 mm (0.
CRANKSHAFT ASSEMBLY 4. Check: • Crankshaft sprocket Damage/wear → Replace the crankshaft. • Bearing Cracks/damage/wear → Replace the crankshaft. 5. Check: • Crankshaft journal Scratches/wear → Replace the crankshaft. • Crankshaft journal oil passage Obstruction → Blow out with compressed air. a. b. 1. 2. 1/4 tooth Correct Timing chain roller Crankshaft sprocket EAS4D3F024 CHECKING THE TIMING CHAIN GUIDE 1.
CRANKSHAFT ASSEMBLY TIP Install the crankshaft assembly with the crankshaft installer pot “2”, crankshaft installer bolt “3”, adapter “4” and spacer “5”. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060 Adapter (M10) 90890-01383 Adapter #2 YU-90062 Spacer 90890-01288 ECA13970 To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Crankcase 1 2 3 4 5 6 7 Shift fork guide bar Shift drum assembly Shift fork-3 (R) Shift fork-2 (C) Shift fork-1 (L) Main axle assembly Drive axle assembly Remarks Separate. Refer to “CRANKCASE” on page 5-53. 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
TRANSMISSION Disassembling the transmission Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Job/Parts to remove 2nd pinion gear 5th pinion gear 3rd pinion gear Circlip/washer 4th pinion gear Main axle Plain washer 1st wheel gear 4th wheel gear Circlip/washer 3rd wheel gear/collar Claw washer 1 Claw washer 2 5th wheel gear Circlip/washer 2nd wheel gear Drive axle Q’ty 1 1 1 1/1 1 1 1 1 1 1/1 1/1 1 1 1 1/1 1 1 Remarks For installation, reverse the removal procedure.
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Shift fork guide bar “1” • Shift drum assembly “2” • Shift fork 3 (R) “3” • Shift fork 2 (C) • Shift fork 1 (L) “4” 2. Remove: • Transmission “5” 3. Check: • Shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends → Replace. EWA12840 WARNING Do not attempt to straighten a bent shift fork guide bar. EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1.
TRANSMISSION EAS26280 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.06 mm (0.0024 in) 4. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 2. Measure: • Drive axle runout (with a centering device and dial gauge) Out of specification → Replace the drive axle. Drive axle runout limit 0.
TRANSMISSION EAS26320 TIP INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1. Install: • Transmission “1” • Shift fork 1 (L) “2” • Shift fork 2 (C) • Shift fork 3 (R) “3” • Shift drum assembly “4” • Shift fork guide bar “5” • Spacer • Right crankcase Check the transmission and shift forks for smooth operation by turning the shift cam with your hand. TIP The embossed marks on the shift forks should face towards the left side of the engine and be in the following sequence: “L”, “C”, “R”. 2.
FUEL SYSTEM FUEL TANK ..................................................................................................6-1 REMOVING THE FUEL TANK ................................................................6-2 CHECKING THE FUEL COCK ...............................................................6-2 CHECKING THE FUEL COCK OPERATION .........................................6-2 CARBURETOR .............................................................................................
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order 1 2 3 4 Job/Parts to remove Seat/front fender Fuel hose (fuel cock side) Fuel tank Clamp Fuel tank shield Q’ty Remarks Refer to “GENERAL CHASSIS” on page 4-1. 1 1 1 1 For installation, reverse the removal procedure.
FUEL TANK EAS26630 REMOVING THE FUEL TANK 1. Remove: • Fuel hose (fuel cock side) ECA14700 Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remaining in it. TIP Before removing the hose, turn the fuel cock to “OFF” and place a few rags in the area under where it will be removed. 2. Remove: • Fuel tank TIP When installing the fuel tank, pass the fuel tank breather hose through the hole in the handlebar protector.
CARBURETOR EAS26720 CARBURETOR Removing the carburetor Order 1 2 3 4 5 6 7 8 9 10 Job/Parts to remove Seat/front fender/rear fender/air filter case Carburetor warmer coupler Air vent hose Fuel hose (carburetor side) Throttle cable cover Throttle cable Clamp Clamp Carburetor Carburetor joint 2 Carburetor joint 1 Q’ty 1 1 1 1 1 1 2 1 1 1 Remarks Refer to “GENERAL CHASSIS” on page 4-1. Disconnect. Disconnect. Disconnect. Disconnect. Loosen. Loosen. For installation, reverse the removal procedure.
CARBURETOR Disassembling the carburetor Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Job/Parts to remove Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Drain hose Throttle stop screw Cover Diaphragm spring Piston valve Jet needle Cover Spring Coasting enricher diaphragm Coasting enricher jet (P. A. J.
CARBURETOR Disassembling the carburetor Order 23 Job/Parts to remove Q’ty 1 Starter jet Remarks For assembly, reverse the disassembly procedure.
CARBURETOR EAS26760 CHECKING THE CARBURETOR 1. Check: • Carburetor body • Float chamber Cracks/damage → Replace. • Float chamber body Contamination → Clean. 2. Check: • Fuel passages Obstruction → Clean. 5. Check: • Piston valve “1” Damage/scratches/wear → Replace. • Piston valve diaphragm “2” Cracks/tears → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b.
CARBURETOR 8. Check: • Jet needle “1” Bends/wear/damage → Replace. • Clip groove Free play/wear → Replace. 12. Check: • Hose joints Cracks/damage → Replace. 13. Check: • Air vent hose • Fuel hose • Drain hose Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. 9. Check: • Main jet “1” • Pilot jet “2” • Needle jet “3” • Needle jet holder “4” • Starter jet “5” • Coasting enricher jet (P. A. J. 2) “6” Bends/damage/wear → Replace. Obstruction → Clean.
CARBURETOR 3. Install: • Carburetor c. If the float height is not within the specification, check the valve seat and needle valve. d. If either is worn, replace the valve seat, needle valve and O-ring as a set. e. If both are fine, adjust the float height by bending the float tang “1” on the float. f. Recheck the float height. TIP Align the projection “a” on the carburetor with the slot “b” in the carburetor joint. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: • Throttle cable • Throttle cable cover 5.
CARBURETOR 6-9
ELECTRICAL SYSTEM IGNITION SYSTEM.......................................................................................7-1 CIRCUIT DIAGRAM................................................................................7-1 TROUBLESHOOTING ............................................................................7-3 ELECTRIC STARTING SYSTEM..................................................................7-5 CIRCUIT DIAGRAM................................................................................
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27100 CIRCUIT DIAGRAM 7-1
IGNITION SYSTEM 1. Pickup coil 2. Stator coil 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 10.CDI unit 11.Ignition coil 12.Spark plug 24.Engine stop switch 28.
IGNITION SYSTEM EAS27130 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). TIP • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover 1. Check the fuse. Refer to “CHECKING THE FUSES” on page 7-33. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-33. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3.
IGNITION SYSTEM 8. Check the stator coil. Refer to “CHECKING THE STATOR COIL” on page 7-40. NG→ Replace the stator assembly. OK↓ 9. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the main switch. OK↓ 10.Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the handlebar switch. OK↓ 11.Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the neutral switch. OK↓ 12.Check the clutch switch.
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM 7-5
ELECTRIC STARTING SYSTEM 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 13.Starting circuit cut-off relay 14.Clutch switch 18.Neutral switch 24.Engine stop switch 25.Start switch 28.
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed).
ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Fuse 3. Main switch 4. Engine stop switch 5. Starting circuit cut-off relay 6. Clutch switch 7. Neutral switch 8. Start switch 9. Starter relay 10.
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. TIP • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover 1. Check the fuse. Refer to “CHECKING THE FUSES” on page 7-33. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-33. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the starter motor operation.
ELECTRIC STARTING SYSTEM 8. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the main switch. OK↓ 9. Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the handlebar switch. OK↓ 10.Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the neutral switch. OK↓ 11.Check the clutch switch. Refer to “CHECKING THE SWITCHES” on page 7-29. NG→ Replace the clutch switch. OK↓ 12.Check the start switch.
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-11
CHARGING SYSTEM 2. Stator coil 3. Rectifier/regulator 5. Battery positive lead 6. Battery 7. Fuse 28.
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. TIP • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover 1. Check the fuse. Refer to “CHECKING THE FUSES” on page 7-33. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-33. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the stator coil.
CHARGING SYSTEM 7-14
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-15
LIGHTING SYSTEM 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 21.Tail/brake light 23.Light switch 26.Headlight relay 27.Headlight 28.
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, tail/brake light. TIP • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover 1. Check the each bulbs and bulb sockets condition. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 732. NG→ Replace the bulb(s) and bulb socket(s). OK↓ 2. Check the fuse. Refer to “CHECKING THE FUSES” on page 7-33. NG→ Replace the fuse. OK↓ 3. Check the battery.
LIGHTING SYSTEM 7. Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 7-15. NG→ Properly connect or repair the lighting system’s wiring. OK↓ This circuit is OK.
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-19
SIGNALING SYSTEM 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 17.Neutral indicator light 18.Neutral switch 19.Rear brake light switch 20.Front brake light switch 21.Tail/brake light 28.
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: brake light or an indicator light. TIP • Before troubleshooting, remove the following part(s): 1. Seat 2. Front fender 1. Check the fuse. Refer to “CHECKING THE FUSES” on page 7-33. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-33. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the main switch.
SIGNALING SYSTEM 3. Check the entire signaling system’s wiring. Refer to “CIRCUIT DIAGRAM” on page 7-19. NG→ Properly connect or repair the signaling system’s wiring. OK↓ This circuit is OK. The neutral indicator light fails to come. 1. Check the neutral indicator light bulb and socket. Refer to “CHECKING THE BULBS AND BULB SOCKETS” on page 732. NG→ Replace the neutral indicator light bulb, socket or both. OK↓ 2. Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-29.
CARBURETOR HEATING SYSTEM EAS27490 CARBURETOR HEATING SYSTEM EAS27500 CIRCUIT DIAGRAM 7-23
CARBURETOR HEATING SYSTEM 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 15.Thermo switch 16.Carburetor warmer 28.
CARBURETOR HEATING SYSTEM EAS27510 TROUBLESHOOTING The carburetor heating system fails to operate. TIP • Before troubleshooting, remove the following part(s): 1. Seat 2. Front panel 3. Front fender 4. Rear fender 5. Side cover 1. Check the fuse. Refer to “CHECKING THE FUSES” on page 7-33. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-33. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the main switch.
CARBURETOR HEATING SYSTEM 7-26
ELECTRICAL COMPONENTS EAS27972 ELECTRICAL COMPONENTS 7-27
ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Handlebar switch 5. CDI unit 6. Starter relay 7. Fuse 8. Battery 9. Tail/brake light 10.Headlight relay 11.Starting circuit cut-off relay 12.Thermo switch 13.Carburetor warmer 14.Starter motor 15.Pickup coil/stator assembly 16.Neutral switch 17.Rear brake light switch 18.Ignition coil 19.Spark plug 20.Headlight 21.Rectifier/regulator 22.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 7-29
ELECTRICAL COMPONENTS 1. 2. 3. 4. 5. 6. 7. 8. 9.
ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELECTRICAL COMPONENTS hands away from the bulb until it has cooled down. EAS27990 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. No continuity → Repair or replace the bulb, bulb socket or both. ECA14380 • Be sure to hold the socket firmly when removing the bulb.
ELECTRICAL COMPONENTS Checking the condition of the bulb sockets The following procedure applies to all of the bulb sockets. 1. Check: • Bulb socket (for continuity) (with the pocket tester) No continuity → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. TIP Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Pocket tester 90890-03112 Analog pocket tester YU-03112-C b.
ELECTRICAL COMPONENTS 1. Remove: • Seat • Battery cover Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Battery leads (from the battery terminals) Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NOT SMOKE when charging or handling batteries.
ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehicle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
ELECTRICAL COMPONENTS TIP TIP Voltage should be measured 30 minutes after the machine is stopped. Voltage should be measured 30 minutes after the machine is stopped. b. Connect a charged and AMP meter to the battery and start charging. b. Connect a charger and AMP meter to the battery and start charging. c. Make sure that the current is higher than the standard charging current written on the battery. TIP Set the charging voltage at 16–17 V.If the setting is lower, charging will be insufficient.
ELECTRICAL COMPONENTS 9. Lubricate: • Battery terminals Starting circuit cut-off relay Recommended lubricant Dielectric grease 10. Install: • Battery cover • Seat Refer to “GENERAL CHASSIS” on page 4-1. 1. 2. 3. 4. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, replace the relay.
ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/ yellow “2” No continuity Positive tester probe → black/ yellow “2” Negative tester probe → sky blue “1” c. Measure the spark plug cap resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28090 CHECKING THE IGNITION COIL 1. Check: • Primary coil resistance Out of specification → Replace. Primary coil resistance 0.18–0.28 Ω ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ELECTRICAL COMPONENTS Secondary coil resistance 6.32–9.48 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the spark plug cap from the ignition coil. b. Connect the pocket tester (Ω × 1k) to the ignition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C 2. Spark plug cap c. Set the main switch to “ON”. d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.
ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.688–1.032 Ω (W–W) b. Measure the pickup coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Connect the pocket tester (Ω × 1) to the stator coil coupler as shown. EAS28940 CHECKING THE STARTER MOTOR OPERATION 1.
ELECTRICAL COMPONENTS EAS28170 • Positive tester probe Black “1” • Negative tester probe Black “2” CHECKING THE RECTIFIER/REGULATOR 1. Check: • Rectifier/regulator output voltage Out of specification → Replace the rectifier/regulator. Rectifier/regulator output voltage 14 V at 5000 r/min ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the engine tachometer to the ignition coil. b. Connect the pocket tester (AC 20 V) to the rectifier/regulator coupler as shown.
ELECTRICAL COMPONENTS EAS28310 CHECKING THE CARBURETOR WARMER 1. Check: • Carburetor warmer resistance Out of specification → Replace. Carburetor warmer resistance 6–12 Ω ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the carburetor warmer from the carburetor. b. Connect the pocket tester (Ω × 1) to the carburetor warmer as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe Carburetor warmer terminal “1” • Negative tester probe Carburetor warmer body “2” c.
ELECTRICAL COMPONENTS 7-43
TROUBLESHOOTING TROUBLESHOOTING ..................................................................................8-1 GENERAL INFORMATION .....................................................................8-1 STARTING FAILURES ............................................................................8-1 INCORRECT ENGINE IDLING SPEED .................................................8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................8-2 FAULTY GEAR SHIFTING ................................
TROUBLESHOOTING • • • • • • • • • EAS28451 TROUBLESHOOTING EAS28460 GENERAL INFORMATION TIP The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
TROUBLESHOOTING Fuel system 1. Carburetor • Faulty diaphragm • Incorrect fuel level • Loose or clogged main jet • Improper jet needle clip position • Deteriorated or contaminated fuel EAS28490 INCORRECT ENGINE IDLING SPEED Engine 1. Cylinder and cylinder head • Incorrect valve clearance • Damaged valve train components 2. Air filter • Clogged air filter element • Loosen air filter joint EAS28530 FAULTY GEAR SHIFTING Fuel system 1.
TROUBLESHOOTING • Incorrect oil level • Incorrect oil viscosity (low) • Deteriorated oil • • • • • • • Clutch drags 1. Clutch • Unevenly tensioned clutch springs • Warped pressure plate • Bent clutch plate • Swollen friction plate • Bent clutch push rod • Damaged clutch boss • Burnt primary driven gear bushing • Loose clutch boss nut 2.
TROUBLESHOOTING • • • • • • Faulty battery Faulty rectifier/regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired Tail/brake light does not come on • Wrong tail/brake light bulb • Too many electrical accessories • Hard charging • Incorrect connection • Improperly grounded circuit • Poor contacts (main or light switch) • Burnt-out tail/brake light bulb Tail/brake light bulb burnt out • Wrong tail/brake light bulb • Faulty battery • Faulty rectifier/regulat
EAS28740 WIRING DIAGRAM YFM25RY/YFM25RSEY/ YFM25RSE2Y 1. Pickup coil 2. Stator coil 3. Rectifier/regulator 4. Main switch 5. Battery positive lead 6. Battery 7. Fuse 8. Starter relay 9. Starter motor 10. CDI unit 11. Ignition coil 12. Spark plug 13. Starting circuit cut-off relay 14. Clutch switch 15. Thermo switch 16. Carburetor warmer 17. Neutral indicator light 18. Neutral switch 19. Rear brake light switch 20. Front brake light switch 21. Tail/brake light 22. Handlebar switch 23. Light switch 24.
YAMAHA MOTOR CO., LTD.
WIRING DIAGRAM YFM25RY/YFM25RSEY/YFM25RSE2Y
